Method of making composite corrugated and solid fiber board



P. F. BOEYE 2 Sheets-Sheet 1 Original-Filed March 7, 1927 NE fi m lamw N R mw Sept. 1, 1931.

METHOD OF MAKING COMPOSITE CORRUGATED AND SOLID FIBER BOARD P. F. BOEYE Sept. 1, 1931.

METHODOF MAKING COMPOSITE CORRUGATED AND SOLID FIBER BOARD Original File ad March '7. 1927 2 Sheets-Sheet 2 7 a hi e s ow ng S ta e-mea def 1 m Pressi g th iqQr uge onsand io sol thtymgi H Patente Sept. 1, 1931 UNITED STATES PATENT OFFICE".

PAUL 1E. BOEYE, OF ST. PAUL, MINNESOTA, ASSIGNOR '10 WALDORF IAPER PRODUCTS COMPANY, OF ST. PAUL, MINNESOTA, A CORPORATION OF MINNESOTA.

METHOD OF MAKING- COMPOSITE COBRUGATED AND SOLID FIBER BOARD Application filed larch 7, 1927, Serial No. 173,484. Renewed December 29, 1930.

In the manufacture of paper or strawboard containers, in order to reduce the weight of the containers to a minimum, it has been common practice to use sheet material having a corrugated layer and at least one surface layer of plain board. Such corrugated board is cut and creased to form blanks of suitable size and shape and is then assembled in box form by securing the blanks together with an adhesive or with metallic fasteners. Metallic fasteners are preferred in the construction of most shipping containers because of the greater speed and lower cost of the securing operation. However, such fasteners are readily torn free from corrugated board of ordinary construction, and in order to produce a strong box, provision must be made for reinforcin the portions of such board through w ich the fasteners are driven.

It is the object of'the present invention to produce economically a composite board having substantially the lightness of corrugated board and formed with solid portions adapted to securely hold wire staples or other metallic fasteners. I The board of this invention may be made from sheets of paper or straw board, such as those commonly used in the construction of corrugated board, and the greater part of the board is corrugated. The portions of the board which are solid have the various layers or sheets secured together without substantial openings between them, and may be located wherever the flanges or other parts to be secured are desired.

lhe invention will be best understood by reference to the accompanying drawings in which Figure 1 is an end view of my improved board; Fig. 2 is a plan view of a fragmentary portion of the same with one of the liner or surface sheets removed or omitted; Fig. 3 is a diagrammatic side elevation of a suitable machine for forming the board; Fig.

-- 1 6s a- I et ilr se i nal Minuetkewer the; line 4-4 of Fig. 3; Fig. 5 is a sectionztakeni- L's-oa s linewfii tl t s men a ysection take ,i ;-ia-.lr;- F g-.f(- a-plauview ite-p rt o-t portions of the sheet and Fig. 8 is a side elevation of said part of the machine.

As shown in Figs. 1, 2, 5 and 6, my improved board has a corrugated core 9 made of paper or straw stock, at least one surface sheet orliner 10 of plain board, and in the forms shown in Figs. 1- and 6. a second surface sheet or liner 11. The liners 10 and 11 are secured in the corrugated parts of the board to the adjacent extremities or convex portions of the corrugations in the core 9 by adhesive. Solid portions 12 are formed to receive wire fasteners or other securing means. These portions 12 may be constructed most economically in a machine like that hereinafter described, wherein adhesive is applied to limited strips between the liners and corugated core and then these strips or portions of the board are compressed to form relatively thin, solid and tough portions, extending transverse the corrugations.

My improved method for constructing such composite board may be. carried out to advantage in a machine of the type in wide use in the construction of well known forms of corrugated board. Such a machine, together with my novel attachments to form my improved board, is shown diagrammatically in Figs. 8. 4, 7 and 8. In this'machine, the sheet for forming the corrugated core 9 is supplied from a roll 13, said sheetbeing fed continuously into the machine. This sheet passes'over a suitable guide roller adjacent to a heating element 14, where the sheet is steamed preparatory to being corrugated between a pair of corrugating rolls 15. After passing between these rolls where it is corrugated, the sheet 9 is passed around the periphery of a large drum 16 having a surface which is corrugated to correspond with the corrugations on the rolls 15 and is then delivered to a second drum 17. As the corrugated sheet 9 passes towards the lower periphery of the drum lti' the outer-extremities forc ohvezi tips, of the corrugatidns receive "1011 :1'8, liquid ad isaid ro: "fr

esliveri'being upplied Y ishsuppliedizfrom h lt' t isicauni over. suitable, g d' rollers and a heating roller 21 to a roll 22, adjacent to the periphery of the drum 16.

' This roll 22 applies a sheet 11 to the corrugated sheet 9 upon the tips of the corrugations, which have previously been supplied with adhesive from the roll 18. Thus, the corrugated core 9 and liner '11 are carr ed around the drum 16 together and are dehvplied from a roll 25 and passes thence oversuitable guide rollers and a heated drum 26 to a roller 27, which delivers it to the upper periphery of the drum 17 Now the liner 10 is applied to the corrugated sheet 9 upon the convex surfaces previously moistened with adhesive from the roll 23. The assembled board then passes beneath a series of hot plates 28, against which it is held by the bristles of a series of brushes 29. During the passage of the sheet beneath the heated plates 29, the adhesive is allowed to set and the continually moving sheet is finally delivered at the end of the machine where it may be'cut into blanks of the desired size.

To form the solid portions 12 of the sheet, I supply additional adhesive between the layers of these portions by means of nozzles 30 and 31 and then compress these portions by means of a series of belts 32 operating in contact therewith and firmly pressed against the board by pressure bars 33. The nozzles 30 are mounted'upon a pipe 34: adapted to supply liquid adhesive thereto under pressure. The nozzles 30 are so located and operated that they continuously spray adh'c sive upon limited strips or bands of the sheet 11 before said sheet is'applied to the corrugated sheet 9. The nozzles 31 are similarly supplied with liquid adhesive under pressure and are arranged to apply the same in a continuous film upon narrow portions of the corrugated sheet 9, on its side opposite to that to which the sheet 11 is applied. To the portions of the corrugated sheet supplied with adhesive from the nozzles 31, the second surface sheet 10 is applied. Thus, additional quantities of adhesive a re applied continnously between the several sheets 9, 10 and 11 and only upon the limited portions thereof, which are later compressed under the action of the belt 32.

As best shown in Figs. 7 and 8, the belts 32 are arranged beneath the longitudinal portions of the sheet which are to be compressed. -Each belt is supported upon a pair of pulleys 35, said pulleys being, in turn, supported upon shafts 36 and 37, extending of the several upper runs of the belts 32 to press said runs against the portions of the sheet to be compressed. The pressure bars 33 are carried upon transverse members 39, which are adjustable vertically upon supporting screws 40. Longitudinal frame members 410i the machine are perforated to receive the screws 40. Suitable nuts 42 threaded upon said screws are arranged to engage the frame members 41, being adapted to be manipulated to raise and lower the screws 40 carrying the members 39 and pressure bars 33. In the spaces between the belt 32, the corrugated sheet is supported and firmly held in contact with the heated plates 28 by the series of brushes 29 which are mounted upon a table 43.

In operation, as will now be readily understood, the liner sheets 10 and 11 and the corrugated core 9 are continuously drawn from the rolls 13, 20 and 25. The inner surface of the liner 11, along the strips of board to be solidified, is continuously supplied with adhesive from the nozzles 30 and the corrugated core on the opposite side of the sheet is similarly supplied with continuous films of adhesive from the nozzles 31. Subsequently, when the sheets have been brought together at the upper periphery of the drum 17, they are passed beneath the heated plates 28, where the portions 12 of the board are compressed and dried to retain their thin form. As the sheet passes beneath the heated plates 28, the pressure of the belts 32-crushes the corrugations along the bands or strips previously supplied by the nozzles 30 and 31, with sufficient adhesive to retain the compressed form. Thus, within the portion -12 of the board, the surface sheets are glued in a continuous path to the liner to form thin, solid portions without substantial openings between the surface sheets. It will be evident that the finished sheet may be cut longitudinally along a line like that indicated by the numeral ll in Fig. 2 to form two sheets. eachboard of common type. The belts 32 and nozzles 30 and 31 may be located opposite any portion of the sheet where it is desired to locate the solid portions. By merely omitting the liner 11 and rendering the nozzles 30 inoperative, a sheet like that shown in Figs. 2 and 5 may be formed.

Having described my invention what I claim as new and desire to protect by Letters Patent is:

1. The method of forming a board from a corrugated sheetand at least one plain sheet which consists in applying between and to a fractional, longitudinal band of said sheets a continuous film of adhesive and before said adhesive sets, crushing the corrugations in the portion of the board containing'said film to form a board having a substantially solid portion extending continuously across the corrugations and a portion having openings between said sheets.

2. The method of forming a board from a corrugated sheet and at least one plain sheet which consists in applying between said sheets a continuous film of adhesive, then bringing said sheets together, face to face, and then, before said adhesive dries, compressing a portion of the board containing said film to form a board having a substantially solid band extending across said corrugations and a corrugated portion.

3. The method of forming a board from a corrugated sheet and at least one plain sheet which consists in applying between said sheets a continuous film of adhesive to a portion of the adjacent surfaces of said sheets and a nonseontinuous film of adhesive to the convex portions of the corrugations, the-n bringing said sheets together, face to face to cause them to adhere to each other, and before said adhesive sets compressing the portion of the board containing said continuous film to form a board having a substantially solid portion and a portion having openings between the sheets,

4. The process of forming a board from a plurality of sheets, which consists in applying continuous film of adhesive to one of said sheets, corrugating another of said sheets, applying adhesive to the convex portions only of the corrugations, bringing said sheets together with the adhesive upon the abutting surfaces thereof, then While said adhesive is' gummy applying pressure to the portionv of the board containing said continuous film of- 6. The process of forming aboard from a plurality of sheets, which comprises corrugating one of said sheets, applying liquid adhesive between saidsheets, along-longitudinal bands, applying adhesive only to the convex portions of other parts of the corrugated sheet, bringing said sheets together with the adhesive upon the abutting surfaces thereof, then while the adhesive is moist, crushing the corrugations containing said longitudinal bands of adhesive and allowing the adhesive to dry to thereby form a board having a corrugated portion and a relatively solid portion extending continuously across said corrugations.

7. The method of forming a board from a plurality of sheets which comprises, corrugating one of said sheets, applying liquid adhesive between said sheets, bringing said sheets together with the adhesive upon the abutting surfaces thereof, then while the adhesiveis moist crushing the corrugations along fractional, longitudinal bands of the board extending transverse said corrugations and allowing the adhesive to set to thereby form a board having a corrugated portion and relatively solid portion.

8. The method of forming a board from a corrugated sheet and at least one plane sheet which comprises, applying adhesive to the corrugated sheet in a quantity in excess of that required to secure the corrugations to the other sheet, bringing said sheets together with the adhesive on the abutting surfaces then, while the adhesive is moist, crushing the corrugations along fractional, longitudinal. bands of the same and allowing the adhesive to set to thereby form a board having a corrugated portion and a relatively solid portion in which the crushed corrugations are secured in crushed relation to the plane sheet.

9. The continuous process of forming composite corrugated and solid fiber board from separate, moving sheets which comprises, corrugating one of said sheets, applying adhesive to portions of one of said sheets, bringing the sheets together with said adhesive between them, then, while the adhesive is moist; crushing the corrugations in a selected por tion of the composite board while maintain ing said sheets in contact with each other and in continuous motion and allowing said adhesive to set.

10. The continuous process of forming composite corrugated and solid fiber board from separate moving sheets which comprises, corrugating one of said sheets tranS- verse its direction of movement, applyin adhesive to, portions of said corrugated s eet," bringing a second sheet into contact with said adhesive, then, while the adhesive is moist, crushing the com-u etions in a; selected, frac-' tional portion of t e composite board while maintaining said sheets in contact with each other and in continuous motion and allowing said adhesive to set. v In testimony whereof, I have hereunto signed my name to this sfiecification,

. v PULEBOEYE. 

